Ignition distributor connector

Transcription

Technical Information Sheet no. 5
CONNECTOR SYSTEMS FOR
IGNITION CIRCUITS
A few words of introduction
40,000 volts, temperatures up to 250 °C, vibration, salt water,
road dust, cleaning agents ... these are just a few of the permanent
stresses to which connectors and ignition cables are subjected dayin, day-out. Ignition lead sets bearing the Beru name are therefore
constructed to be totally waterproof, resistant to corrosion, stress
free and as a special feature, a reliable contact system. Beru ignition
lead sets are manufactured to original equipment quality and,
where necessary, suppressed in accordance with the VDE standard.
This brochure explains how you can repair or totally replace ignition
lead sets reliably and professionally with the help of the Beru ZAZ 3
workshop range. The range enables workshops for the very first
time to employ the same attachment techniques used as standard
in mass manufacture.
2
Index of Contents
Beru ignition cable systems
Instructions on how to use the brochure
and the ZAZ 3 workshop range
CopperCable connector systems
BMW
Mercedes Benz
Opel
VW/Audi/Seat
Universal
PowerCable connector systems
Waterproof mouldings
Installation aids
Workshop tips
Page
3
5
6
8
12
15
16
18
19
21
22
23
PowerCable
Inner silicon insulation (core)
Optimum insulation, prevents power
loss, highly flexible
High-grade steel resistor wire
For optimum high-voltage transmission
and consistent resistance values
Textile braiding
Strengthens the ignition
cable, guarantees high
tensile strength, increasing
the service life.
Ferro-magnetic silicon for effective
and reliable suppression
Reliability comes from updating
with the right ignition cables
European automobile manufacturers use three different types of OE
ignition cable systems in their vehicles: either resistance ignition
circuits with wire resistance in the cable, with carbon resistance in
the cable or ignition circuits with a copper core on which the
suppression resistance is integrated in the connectors.
Up to just a few years ago bakelite connectors and PVC ignition
cables were still being installed in many vehicles; the spark plug
connectors used in these systems had no protection whatsoever
against water ingress and dust/dirt. So if the system requires
updating we recommend ignition cables and connectors from Beru
for your customers: for copper ignition cables, Beru CopperCable, for
resistor ignition cables, Beru PowerCable. These quality cables
guarantee precision ignition sequence, optimum engine performance
and low fuel consumption - to the same OE supplier quality.
The following pages give you information and tips on repairing and
assembling together complete Power and CopperCable systems.
High temperature resistant, durable
silicon sheath
(--60 °C to +250 °C)
Provides effective protection against oil, petrol,
salt water, acid, heat and other external influences.
Modern connection materials from
Beru offer many advantages
Previously Today
Ignition cables
PVC
Silicon
Safe voltage
15,000 V
40,000 V
Temperature resistance (max.)
80 °C
250 °C
Protection against water and moisture limited
100%
CopperCable
Original spark plug contact
Fits M4 or SAE spark plug
Precision co-ordinated loss resistance
designed to suit the ignition system, conforms
to VDE standard
Metal screening on Audi,
Mercedes, Seat, VW
extra thermal protection and
radio interference suppression
Epoxy resin casing
temperature resistant,
voltage-proof
Original ignition cable
attachments
– BMW locating sleeve (non-detachable)
– Mercedes screw connection (M3)
– Audi, Seat, VW saw-tooth sleeve
Silicon safety tube
for water and dustproof fit, highly
voltage resistant
Silicon safety cap
highly voltage resistant
Silicon ignition cable, talcum-coated
glass fibre reinforced, copper core, high
voltage resistant, highly flexible, highly
temperature resistant
Ignition distributor contact
3
Ignition cable contact options
Description
Application
Order no.
Packaging unit
Locating sleeves
primarily
Audi
VW
BMW
0 901 300 001
1 box =
100 units
Saw-tooth sleeves
primarily
Audi
VW
Seat
0 901 300 002
100 units
M3 threaded sleeves
primarily
Mercedes-Benz
Porsche
0 901 300 003
100 units
SAE ignition cable sleeves
primarily
Ford
Opel
Fiat
0 901 300 004
100 units
SAE 90° ignition cable sleeves
primarily
Ford
Opel
0 901 300 007
100 units
Ignition distributor sleeves
Universal for
DIN connector pin
0 901 300 005
100 units
Description
Order no.
Packaging unit
0 300 800 023
25 m roll
0300 800 021
25 m roll
0 300 800 002
50 m packed in boxes
Order no.
Packaging unit
0 300 800 030
25 m roll
(inklusive of 100 contact needles
0 901 300 010)
Copper ignition cable
Silicon ignition cable
7 mm dia. black
7 mm dia. red
PVC ignition cable
7 mm dia. black
Resistance cable (5,64 k/m)
Description
PowerCable silicon
7 mm blue
Category
B
C
D
E
F
4
Insulation
Temperature resistant at
Thermal ageing (3000 h)
Thermal overload (1 h)
105 °C
120 °C
155 °C
180 °C
220 °C
120 °C
155 °C
180 °C
220 °C
250 °C
PVC
EPP, Hypolon, EPDM
EVA
Silicon
Silicon
The ZAZ 3 workshop range for quick and
reliable ignition cable repairs
Order No. 0 890 300 003
The range includes:
Crimping pliers
Locking sleeves
Saw-tooth sleeves
M3 threaded sleeves
SAE ignition cable sleeves
SAE ignition cable sleeves,
angled
Guide: The right “contact” for
every vehicle
What you need:
Ignition distributor sleeves
Waterproof mouldings G 1 PK
Waterproof mouldings GS 7 and
GW 10
Inserting tool
Detailed instructions for use
Installation oil
The ZAZ 3 crimping pliers:
an indispensable tool
For repairs or replacement, Beru offers a practical tool which will
enable you to crimp the sleeves onto the ignition cables to the same
standard as the original fittings:
The Beru ZAZ 3 workshop range
Beru ignition cable from the roll
Beru connectors
The Beru ZAZ 3 crimping pliers
And how it’s done:
The key advantages:
1. Select the correct connectors or the waterproof moulding with the
help of the diagrams on the following pages.
2. Read the description on the relevant ignition cable contacts.
(Alongside this description you will find the order number and
packaging unit.)
3. Remove the complete ignition harness (“old”) or individual
cable and measure out the cable lengths (marking the cablecylinder order beforehand if required).
4. Using the Beru ignition connectors, sleeves and the Beru ZAZ 3
crimping pliers, make up the corresponding ignition cable set
(Installation Instructions on Page 6, Page 19).
• The compression pressure, which is important to ensure a reliable
connection, can be achieved quickly and easily during the crimping
process.
Beru ZAZ 3 crimping pliers
• This is the only way to achieve the stipulated withdrawal values.
• This is the only way that OE quality connectors can be used.
• This is the only way to carry out repairs on the engine itself
without any problems. The cable system does not have to be
replaced.
Markings for checking the
stripping
Cable squeeze M3
threaded sleeve
Pull release
saw-tooth sleeve
Pull release
locating sleeve
and M3
threaded sleeve
Order No. 0 890 300 001
Release the
lock
Cable squeeze
saw-tooth sleeve
Cable squeeze
locating sleeve
Cable squeeze SAE ignition cable
sleeve, ignition distributor sleeve
5
CopperCable connector systems
Audi, BMW, Mercedes, Seat and VW vehicles are fitted with technically superior high-quality copper ignition circuit systems as standard.
Silicon-coated or injection moulded connectors, with integrated suppression resistance for waterproof protection, are two of the features of
this engineering. The design ensures optimum heat protection, is resistant to disruptive discharge up to 40,000 volts and vibration-resistant.
The suppression (in accordance with VDE) is co-ordinated to suit the ignition system of the vehicle manufacturer. Thanks to their silicon
coating the ignition cables are highly flexible up to 250 °C.
Installation Instructions for CopperCable
How the ignition cables are attached for total reliability
as shown by the example of a Mercedes-Benz connector with M3 threaded sleeve
6
Remove the insulation at the end of the ignition cable
with the help of an appropriate tool (wire cutter). An
easy way to check the correct length of cable has been
stripped, i.e. 6.8 mm, is to place it in the head of the
pliers.
1
2
3
To produce the connection between sleeve and copper
core, proceed as follows: first place the ignition cable
with sleeve into the crimping pliers - so that the thread
protrudes out of the plier jaws. Then press the pliers
together until they self-release.
4
5
6
Fitting the spark plug connector or the ignition distribution connector: apply installation oil to the ignition
cable and the internal silicon seal on the connector.
Now carefully position the M3 threaded sleeve onto
the ignition cable. We recommend that you twist the
fine copper wires slightly beforehand so they do not splay
out when being connected, instead they all slot into the
threaded section of the connection sleeve.
The connection between the sleeve and silicon outer
sleeve is created during the second crimping process.
Use the crimping pliers in position 1. Insert the sleeve in
such a way that it closes together with the rear edge of the
pliers, then press the pliers together until they self-release.
The ignition cable must now be screwed into the
connector. Finally, unscrew it by one quarter revolution
to make it easier to subsequently unscrew the connector.
For secure copper ignition cable connections
Connecting the locating sleeve:
1. Strip ignition cable using appropriate tool.
Check the measurement, 5.5 mm, by positioning on head of pliers.
3. Attaching:
as shown on Page 6.
2. Insert locating sleeve onto the ignition cable as far as it will go.
Attaching the saw-tooth sleeve:
3. Attaching:
as shown on Page 6.
2. Insert saw-tooth sleeve onto the ignition.
Attaching the M3 threaded sleeve:
3. Attaching:
as shown on Page 6.
2. Insert M3 threaded sleeve onto the ignition cable as far as it will go.
Attaching the SAE ignition cable sleeve:
1. Cut ignition cable cleanly.
3. Attaching:
a) Insert ignition cable with sleeve into pliers (see diag. 4).
b) Press pliers together until they self-release (see diag. 4, Page 6).
Attaching the angled SAE ignition cable sleeve:
1. Strip ignition cable using appropriate tool and bend cable core
back (measurement approx. 15 mm).
3. Attaching:
a) Insert ignition line with sleeve into pliers (see diag. 4).
2. Attach angled SAE ignition cable sleeve to ignition cable so that the
cable core comes into contact with the body of the sleeve.
Attaching the ignition distributor sleeve:
1. Cut ignition line cleanly.
2. Attach DIN sleeve to the ignition cable.
Beru EFS 7 inserting tool
Order no. 0 890 300 002
3. Attaching:
a) Insert ignition cable with sleeve into pliers (see diag. 4).
The Beru EFS 7 tool is needed for attaching the locating sleeve to the connector
securely and quickly. Push the ignition cable into the tool using your thumbs; locating
sleeve is now positioned in the tool. Apply installation oil. Insert ignition cable into
the spark plug connector or distributor connector with the help of the tool until you
hear the engaging pin-connector engage. Withdraw tool.
Installation Instructions for CopperCable
2. Push SAE sleeve with pin onto ignition cable.
7
BMW
Spark plug connectors
Spark plug
SW 21
SW 16/21
4 mm
4 mm
Description and Order no.
Ignition cable
ZLE 004/3
0 300 012 002
PVC/silicon ignition cable
with saw-tooth contact
ZLE 147
0 300 032 101
ZLE 166
0 300 032 107
with locating sleeve contact
Connector Systems
ZLE 185
0 300 132 104
8
SW 16
SAE
ZLE 190
0 300 332 109
Distributor cap
Distributor cap with 8 mm DIN
connection, 27 kV engineering
✱
Ignition cable
VESO 112
0 300 513 116
VESO 113
0 300 513 113
with M3 contact
VES 101
0 300 413 107
BMW
Ignition distributor connector
VESO 118
0 300 513 141
✱
Distributor cap with 4 mm
VES 107
0 300 413 113
✱
VESO 117
0 300 513 140
VESO 120
0 300 513 124
with M3 contact
✱
Distributor cap with 4 mm
connection, 30 kV Motronic engineering
VES 106
0 300 413 112
Connector Systems
✱
✱ Fitted as standard
9
BMW
Ignition coil connector
Ignition coil
Ignition coil with 8 mm DIN
Ignition cable
VESO 112
0 300 513 116
VESO 119
0 300 513 122
VES 101
0 300 413 107
VESO 118
0 300 513 141
✱
Ignition coil with 4 mm
VES 107
0 300 513 107
Connector Systems
✱
VES 103
0 300 413 109
with saw-tooth sleeve contact
✱
10
VESO 117
0 300 513 140
VES 106
0 300 413 112
On 4 cylinder engines an induction timer is fitted to
the ignition cable of the 4th cylinder, on 6 cylinder
engines this is fitted to the ignition cable of the 6th
cylinder.
When replacing cables, save the time-consuming and
costly work of refitting an ignition cable with a built-in
pulse timer. Your customer will be grateful to you for
the roughly thirty pounds he saves.
1 Just remove the defective cable only.
the ignition distributor plug on the new
2 Unscrew
CopperCable (spray with Beru installation oil).
3 Drillhand).8 mm hole on the pulse timer (turn drill by
cable with the M3 connection can
4 Thenowignition
be pushed through the pulse timer.
5
Now lubricate the ignition cable with installation
oil.
6
Finally, screw on the ignition distributor connector
of the CopperCable.
BMW
Connector Systems
Tip when installing in BMW with pulse timer for the 4 or 6 cylinder versions
11
MERCEDES-BENZ
Spark plug
Ignition cable
✱
SW 21
4 mm
ZLE 121
0 300 062 102
✱
SW16
SAE
ZLE 135
0 300 152 106
with M3 contact
✱
Connector Systems
SW 21
✱
SW 16
12
4 mm
WBAK 4/14/5
0 300 075 101
Ceramic version for V8 engines
SAE
ZLE 159
0 300 352 108
Spark plug
Ignition cable
MERCEDES-BENZ
✱
SW 16
SAE
ZLE 245
0 300 122 302
with M3 contact
✱
SAE
✱
SW 16
✱
SAE
ZLE 227
0 300 362 106
12 cylinder vehicles
Connector systems
SW 16
ZLE 225
0 300 362 105
Fitted as standard
13
MERCEDES-BENZ
Ignition distributor connectors
Distributor cap
Ignition cable
Distributor cap with 8 mm DIN connection
VESO 113
0 300 513 113
with M3 contact
Distributor cap with SAE connection
VSO 103
0 300 504 101
with M3 contact
M108 A to E
CopperCable
Complete ignition cable for
ignition distributor - spark plug
Distributor cap with M4 connection
M111 A to C
CopperCable
Completion ignition cable for
ignition distributor - ignition
coil
The distributor connectors for the distributor cap with M4 connection cannot
be fitted (crimped) on their own. Beru
therefore supplies complete individual
ignition cables in various lengths. (see
CopperCable List of Applications).
Connector systems
Ignition coil connectors
14
Ignition coil
Ignition coil with 8 mm DIN connection,
standard connector pin
VESO 113
0 300 513 113
Ignition coil with 8 mm DIN connection
with thick connector pin
VSO 105
0 300 504 103
Twin ignition coil
(2 no.)
VS 107
0 300 404 108
Twin ignition coil/connector coil
(2; or 3 no.)
VS 106
0 300 404 107
Ignition cable
with M3 contact
Spark plug
Ignition cable
OPEL
Spark plug connectors for 4 cylinders, 16 valves
ZLE 200
0 300 312 108
SW 16/21
with M3 contact
SAE
Distributor Cap
Ignition cable
VESO 120
0 300 513 124
Distributor cap with M4 connection
16 valve version, 30 kV engineering
VES 114
0 300 413 120
with M3 contact
Ignition cable
VESO 120
0 300 513 124
VES 114
0 300 413 120
with M3 contact
Connector systems
Ignition coils
15
VW/AUDI/SEAT
Spark plug
Ignition cable
16 valve engines
SW 16
SAE
ZLE 168
0 300 332 105
8 valve engines
SW 21
4 mm
ZLE 205
0 300 072 110
V6 engines (Audi)
SW 16
SAE
ZLE 212
0 300 172 107
VR6 engines (Volkswagen)
SW 16
SAE
ZLE 226
0 300 172 108
Connector systems
16
Distributor cap
Ignition cable
Distributor cap
with 8 mm DIN
connection
➝ 7.84
VESO 113
0 300 513 113
with M3 contact
VES 105
0 300 413 111
Distributor cap with
saw-tooth connection
8.84 ➝
VESO 116
0 300 513 119
Ignition coil
Ignition cable
VW/AUDI/SEAT
✱
Ignition coil with
8 mm DIN connection
➝ 7.84
VES 102
0 300 413 108
VESO 116
0 300 513 119
✱
Ignition coil with
saw-tooth connection
8.84 ➝
VES 105
0 300 413 111
Ignition
transformer
6 cylinder
Ignition
transformer
4 cylinder
VESO 116
0 300 513 119
Connector systems
✱
17
UNIVERSAL Connector Systems for vehicles with 8 mm DIN distributor connection
18
Spark plug
SW 16
SW 21
SAE
ZLE 175
0 300 112 101
SAE
ZLE 171
0 300 312 102
SW 16
SW 21
Ignition cable
with M3 contact
Distributor cap
Distributor cap with
8 mm DIN connection
Ignition cable
VESO 113
0 300 513 113
with M3 contact
VES 108
0 300 413 114
Ignition coil
Ignition cable
Ignition coil with
8 mm DIN connection
VESO 113
0 300 513 113
with M3 contact
For secure Beru PowerCable attachments:
The high-grade steel core of this PowerCable, which is
wound around a silicon carrier, can reliably transmit
high-voltage of up to 40,000 volts. To ensure that this
high ignition voltage also reaches the spark plugs without power loss, the PowerCable is double-insulated
with a highly flexible, internal silicon layer and a
sheath which remains stable, flexible and resistant to
disruptive discharge at temperatures between -60 °C
and +250 °C. This silicon sheath provides effective
protection for the power cable against external
influences such as oil, petrol, salt water and acid.
Between the inner and outer insulation there is a
textile material, providing mechanical strengthening
for the ignition cable.
1
Press the cable together with the thumb and index
finger.
2
Insert the contact pin into the cable between the
insulation and resistor wire.
3
Insert sleeve into the cable (contact pin on the sleeve).
4
Now simply crimp the cable ...
5
then, with the help of the tool and installation oil,
slide into the waterproof cover on the spark plug
connector from below.
Installation instructions for PowerCable
PowerCable connector systems
19
Attaching resistor ignition cables securely
Attaching the SAE ignition cable sleeve:
4. Attach
a) Insert ignition cable with sleeve into pliers.
b) Press pliers together until they self-release.
2. Insert contact pin into the cable between insulation and resistor
wire (see installation tip Page 19).
3. Insert SAE sleeve into ignition cable.
Attaching the angled SAE ignition cable sleeve:
4. Attach
2. Insert contact pin into the cable between insulation and
resistor wire (see installation tip Page 19).
3. Attach angled SAE ignition cable sleeve to the ignition cable so
that the contact pin comes into contact with the sleeve body.
Attaching the DIN ignition cable sleeve:
Installation instructions for PowerCable
4. Attach
2. Insert contact pin into the cable between insulation and
resistor wire (see installation tip Page 19).
3. Attach DIN sleeve to ignition cable so that the contact pin
comes into contact with the sleeve body.
Contact pins * for PowerCable
Order no.
Packaging unit
0 901 300 010
100 nos. in poly bag
* One bag (100 no.) of contact pins is included with every 25 m roll of PowerCable.
20
Waterproof Mouldings
Order no.
Length (mm)
Cable dia.(mm) Internaldia.(mm) Material
Use
G 1 PK
0 010 300 002
32
5+7
15
PVC
Ignition distrib.
G 1 PL
0 010 300 003
50
5+7
15
PVC
Ignition distrib.
G1N
0 010 110 001
40
7
13
Neoprene
Ignition distrib.
G1S
0 010 120 003
38
7
13
Silicon
Ignition distrib.
G2S
0 010 330 003
50
7
15
Silicon
Ignition distrib.
G2P
0 010 100 001
48
7
13
PVC
Ignition distrib.
G3P5
0 010 100 002
25
5
13
PVC
Ignition distrib.
G3P7
0 010 100 003
25
5
13
PVC
Ignition distrib.
G4P7
0 010 100 006
30
5
11
PVC
Ignition distrib.
GWS 7
0 010 020 006
14
–
18
Silicon
Spark plugs
GWS 9
0 010 020 007
27
–
–
Silicon
Spark plugs
GWS 7
0 010 320 002
67
7
10
Silicon
Ignition distrib., Spark plugs
GW 11
0 010 310 005
47
7
–
Silicon
Ignition distrib., Spark plugs
G3S
0 010 120 004
98,5
7
–
Silicon
Spark plugs
Connector systems
Type
21
Helpful tools
Helpful tools
22
Plug extractor
ZSA 2 Order no. 0 890 300 008
Extractor for 16 V connectors
ZSA 4 Order no. 0 890 300 014
Plug extractor
The practical and helpful
Beru spark plug tool
We all know the problem: the engine is hot, the spark plug connector
is difficult to reach - now the spark plugs are supposed to be
changed. If the connectors are pulled off at the cable there is the
risk of the ignition cable being pulled out. Extracting the connector
using the wrong type of pliers will damage the connector. The Beru
solution: special tools which enable you to extract the spark plug
connectors easily.
In years gone by it was all so much easier. In those days car engine
compartments were so large you could almost lose the power units
in them. Changing the spark plugs was no problem at all:
everything was easily accessible and it took just a few minutes to
do the job. Nowadays it’s totally different. Filled to the brim with
electronics, every tiny space is utilised and spark plugs on modern
4-valve engines are located between deep crevices. A minor
operation becomes a fiddly task even for mechanics.
But now even the do-it-yourself mechanic no longer needs to throw
in the towel immediately. The helpful spark plug tools from Beru
make light work of changing plugs. With the help of the tool the
plugs can be carefully tightened and loosened without you injuring
or burning yourself on the engine. The flexible, rubber tool gives the
mechanic “finger-tip sensitivity”, making it easy to avoid damaging
the thread on the cylinder head or spark plugs caused e.g. by
overtightening or using force. The spark plug also sits firmly in the
tool. So damage components or incorrect electrode gap settings are
now a thing of the past.
Spark plug tool
ZMH Order no. 0 890 000 001
Fitting made easier: sharpening the ignition cable
We’re all familiar with the problem of fiddling with
ignition cables which are so difficult to insert into an
ignition distributor connector, spark plug connector or
waterproof cover.
There’s now an amazingly simple solution which
makes installation so much easier for you. The end of
the cable sheath can be sharpened slightly with the
help of a normal pencil sharpener. Then, lubricated
with a little installation oil, the ignition cable can be
slotted easily into the opening provided.
The easy way to fit connectors, with the help of installation oil
This oil quickly dissolves and leaves no residues (Order
no. 0890 300 020).
It is vital not to use glycerine, engine oil, battery grease,
silicon grease, silicon oil or cockpit spray. These
materials are unsuitable and will clog the cables!
Workshop tips
A wide range of greases and oils are used in workshops for fitting spark plug, distributor and ignition coil
connectors to ignition cables. But beware: not all
materials are suitable! So it’s better to be “safe than
sorry”! We recommend Beru special installation oil.
23
Printed in Germany • 04.06.97 • Bestell- Nr. 5 300 001 012
Beru Ruprecht GmbH & Co. KG
Wernerstraße 35, D-71636 Ludwigsburg
Postfach 229, D-71602 Ludwigsburg
Telefon: ++49 71 41/ 1 32- 0
Telefax:++49 71 41/ 1 32 - 350

Ignition distributor connector

Transcription

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